Fresh and cured meat processing and preservation

Steven M. Lonergan , ... Dennis N. Marple , in The Science of Animal Growth and Meat Technology (Second Edition), 2019

Restructured Meat Products

Restructured meat products are ground, flaked ( Fig. 13.4), or chopped and manufactured into steaks, chops, or roast-like products for retail consumers and institutional food preparation. These products have a texture more closely identified with an intact steak or chop than that of a ground product. After particle size reduction, the meat is mixed with salt, phosphate, and protein materials (e.g., egg albumen) or hydrocolloid binders such as alginate, a gum extract from brown seaweed. Salt and phosphate act to solubilize myofibrillar proteins to ensure a stable meat product bind, whereas protein materials and carbohydrate binders serve in retaining the product structure. Then the product is formed into its desired shape, cooked, and packaged for retail markets. The beauty of restructuring is that it affords the use of quality meat that can be transformed into even more valuable products (Fig. 13.5) by the processor. A large percentage of turkey and chicken meat is manufactured into restructured products to form loaves or roasts (Fig. 13.6) and other convenience products. For instance, breast meat is transformed into turkey rolls, steaks, and nuggets (Fig. 13.7).

Fig. 13.4

Fig. 13.4. A machine used to prepare flaked meat before it is manufactured into steaks or chops.

 Courtesy, Iowa State University Meat Science Laboratory.

Fig. 13.5

Fig. 13.5. An example of a restructured pork rib made from boneless pork cuts such as the pork carcass shoulder.

Fig. 13.6

Fig. 13.6. An example of a roast manufactured from chicken breast meat and bacon.

 Courtesy of Smithfield Foods.

Fig. 13.7

Fig. 13.7. Turkey slices or steaks obtained from a quality turkey roast made from portions of turkey breast meat that was transformed into a roast.

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Applications of Alginate as a Functional Food Ingredient

Yimin Qin , ... Fahe Wang , in Biopolymers for Food Design, 2018

3.3.4 Restructured meat products

Restructured meat products include luncheon loaves, roast beef, turkey breast, pork roasts, fish patties, surimi sticks, ham loaf, chicken, and many others that are formed, pressed, rolled, and shaped to ease preparation for foodservice workers and improve eating for consumers. While this technology is often used for processing small pieces of meat and fish products, high-end products, such as duck and veal, are now using it to improve cost effectiveness. At the same time, when busy consumers are maintaining their demand for quick-and-easy meal solutions, foodservice personnel are equally demanding in their requests for cost-effective, easy-to-handle products requiring little preparation. Consumers, delicatessen operators, and restaurateurs insist that products be easily sliced, have the ability to be reheated, provide an attractive appearance, and offer flexibility of use. The restructuring technology is best illustrated in the fabrication of fish, where it is used not only to make use of unfamiliar "trash" fish species but also better to utilize expensive species, such as shrimp.

Building suitable texture into formed comminuted meat, shellfish, or fish products often requires the addition of functional ingredients to obtain the desired palatability. Structure is often developed through the use of hydrocolloidal ingredients or combinations of ingredients. These function to improve the subsequent processing characteristics such as shape retention, final palatability, and cold-forming speeds. Many innovative twists have been employed in reforming fish texture using the basic well-known alginate-calcium salt reaction. Alginate layering simulated the flaky internal appearance of fish fillets. Minced fish, fish flakes, and fish pieces were set in consecutively applied layers by an alginate–calcium gelling reaction, much as the layers of a cake are built up. The layers were then cut on the bias and the slices battered, breaded, and cooked to yield the characteristic diagonal-flake appearance of natural fillets.

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Design of healthier foods and beverages containing whole algae

S. Cofrades , ... F. Jiménez-Colmenero , in Functional Ingredients from Algae for Foods and Nutraceuticals, 2013

Effects on growing rats of diet-enriched restructured meat products containing algae

The effects of diets including restructured meat products containing wakame, nori and sea spaghetti has been evaluated through various enzyme activities and gene expression in growing rats ( Table 19.1). These studies concluded that restructured meat with nori is a hypocholesterolaemic food while that with wakame is an antioxidant food (Schultz-Moreira et al., 2010). The presence of sea spaghetti in restructured meat partially blocked the effect of the hypercholesterolaemic agent, giving rise to a new balance of the antioxidant enzyme expression in the liver of growing rats (Schultz-Moreira et al., 2011).

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Processing and quality control of restructured meat

P. Sheard , in Meat Processing, 2002

17.1 Introduction

A variety of restructured meats have been marketed successfully over the last 30 years in the UK, the USA and elsewhere. The success of these products has arisen from consumer demand for convenience, variety, consistent quality and, also, the economic desirability for the manufacturer to upgrade meat raw materials. Products are referred to, variously, as 'restructured', 'reformed', 'flaked and formed', 'chopped and shaped' and 'chunked and formed' determined to a large extent by the size of the constituent pieces ( Franklin and Cross, 1982; Sheard and Jolley, 1988). The term 'intermediate value products' is also used (Breidenstein, 1982), suggesting that this type of product is perceived by the consumer, and marketed, as intermediate in value between traditional burgers and intact muscle steak.

In the UK, products are usually frozen, may be breaded and coated, and are usually rib or steak-shaped, with an appropriate coined name (e.g. joysteak, grillsteak or ribsteak). Restructured meats may also be used as an alternative to ordinary diced meat in canned meats or ready meals. Some products are sold in a bun or as the main component in a ready meal. The largest, and most easily identified, sector is that for grillsteaks. A UK survey of grillsteak-type products showed that most have a meat content of 93% or above, though some were as low as 55% (Jolley et al., 1988). Beef was the main ingredient in the products surveyed, though restructured ribs are usually pork and there are some lamb products. Poultry meat also features strongly. All the products included in the survey contained salt; phosphate, soya and caseinate were common in products with lower meat contents.

Meat restructuring 'involves the assembly of meat pieces into a cohesive product which aims to simulate or retain the texture of high quality muscle' (Sheard and Jolley, 1988). This definition is useful in that it conveys something of the way in which the products are made: comminution followed by reassembly or the binding together of the constituent pieces. It also prescribes the objective in terms of the desired texture and the way in which that is achieved: either by simulation (which is necessarily the case where the meats have been finely comminuted to a paste or emulsion) or by retaining the typical fibrous texture of good quality whole muscle, as is the case where the piece size is relatively large (e.g. chunked and formed products). Cohesion is developed during cooking by the gelation of meat proteins solubilised during processing by the action of salt.

Most of the published research has emanated from the United States (see for example, Franklin and Cross, 1982; Pearson and Dutson, 1987) where there appears to be a greater use of fresh meat than in the UK and more product is targeted at the food service (catering) sector (Field, 1982), including the armed forces (Shults, 1982). This review, for obvious reasons, focuses on the situation in the UK where the use of semi-frozen meat is more common. Section 17.2 describes the sequence of operations involved in the manufacture of UK-style grillsteaks (tempering, pre-breaking, flaking, mixing, forming and freezing). The same stages, with a few modifications, are employed in the manufacture of restructured roasts and diced meat. Factors affecting product quality are discussed in Sections 17.3-17.6 which highlight the need for accurate temperature control at the pre-break stage and explains the role of salt and phosphate in producing an adequate bind. Also included is some previously unpublished data from this laboratory. Some recent developments are highlighted in Section 17.7.

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Use of cold-set binders in meat systems

J.A. Boles , in Processed Meats, 2011

Phosphates

Phosphates are added to restructured meat products to help solubilize meat proteins and increase water-holding capacity, thereby improving bind and yield of the finished product ( Offer and Trinick, 1983). Phosphates also contribute to flavor stability in cooked products. Phosphates act as metal chelators that can affect the rate of off-flavor development after cooking (Boles and Parrish, 1990). Lawrence and coworkers (2004), however, reported increased off-flavor intensity when whole beef loins had been enhanced with salt (0.2%) and phosphates (0.4%) and stored for 7   days before analysis. Increased levels of phosphate can result in off-flavor development, especially soapy flavors. Phosphates have also been shown to have metallic flavor components (like the taste of a silver spoon) especially when used near their limit (0.5% in many countries).

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Application of Batters and Breadings to Various Substrates

Linfeng Wang , Darrel R. Suderman , in Batters and Breadings in Food Processing (Second Edition), 2011

Battering Restructured Meats

Adhesion and application problems encountered in battering and breading restructured meats are similar to those for battering and breading fish portions since their processing steps are similar. If frozen portions are used, processors should carefully formulate their product, predip, and batter formulas to compensate for frozen surfaces. The processor should also refer to the descriptions of adhesion problems associated with seafood in this chapter (i.e., voids and blow-off). Fresh or tempered meat portions are expected to have a meat surface more conducive to improved batter adhesion. Red meat products sometimes have dark brown marks oozing out on the breading. This is usually caused by myoglobin leaking from the red meat. Phosphates used in predust can aid moisture binding on meat surfaces. More care should be given to the meat marinades and to binders such as soy flour, starch, and/or gums.

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Soy Protein Processing and Utilization

Edmund W. Lusas , Khee Choon Rhee , in Practical Handbook of Soybean Processing and Utilization, 1995

Meat Applications

Meat products are highly prized and attract cost-cutting technologies in all countries. In the United States, soy proteins are used:

1.

As processing aids in the manufacture of frankfurters, sausages, and comminuted meat products

2.

In marinades and tumbling solutions for restructured meats

3.

In injection pumping proteins to increase the weight of intact muscles and cuts

4.

In extruder-texturized flours and concentrates that are rehydrated and used at about the 20% level in hamburgers

Processed Meats

The U.S. Department of Agriculture permits use of up to 3.5% soy flours or concentrates in standard of identity frankfurters, up to 8% soy flour in scrapple and chili con carne, and up to 2% soy protein isolates in standard of identity frankfurters. Soy flours and concentrates can bind up to three times their weight in water, whereas nonfat dry milk solids bind only an equal weight of water. These ingredients reduce shrinkage due to moisture and fat loss during cooking. The use of soy protein isolates globally, in making skin and fat emulsions for later inclusion in processed meats and other applications, is described in detail by Bonkowski (90). Broad latitudes in formulation for processed meats exist outside of the United States, and also within the United States for non–standard of identity meat products.

Restructured Meats.

Principles of restructuring meats are reviewed by Pearson and Dutson (91). Basically, red or poultry meats are flaked or chunked into small pieces, mixed or tumbled with salt and polyphosphates to extract heat-coagulable protein, shaped into loaf pans or other still-forming devices, heat-set at about 68°C (154°F), and cut into desirable shapes and thicknesses. Soy flours, concentrates, and isolates are used at approximately the same levels as in processed meats to improve textural stability and minimize shrinkage.

Pumped Meats.

Brines consisting of water, salt, polyphosphates, and soy protein isolates or functional concentrates are prepared and pumped into muscle cuts using stitch pumps. Various domestic federal regulations apply; for example, hams and corned beef can be pumped to achieve cooked yields of 130%, provided a minimum protein content of 17% is maintained. Reviews on meat pumping technology have been prepared by Bonkowski (90) and Rakes (92).

Extruder-Texturized Soy Proteins.

Texturized soy flours or concentrates may be rehydrated to 18% protein content (60 to 65% moisture content) and used at levels up to 30% reconstituted soy protein in ground meat blends and hamburgers. However, in domestic practice the reconstituted portion usually has been used at about 20%, because of texture and flavor problems accompanying higher levels of meat substitution. Special vitamin- and mineral-fortified texturized soy protein products are required for school lunch and military feeding. Texturized soy proteins are sometimes included in standard of identity canned meat products above the meat requirement to improve product attractiveness.

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CURING | Brine Curing of Meat

F. Shahidi , ... R.B. Pegg , in Encyclopedia of Meat Sciences (Second Edition), 2014

Salt (Sodium Chloride/Potassium Chloride)

Salt is the main ingredient used in all curing mixtures and it is used for the purpose of developing flavor and for solubilizing proteins that are important for emulsion stability of comminuted and restructured meat products. Salt also helps in controlling microbial action in cured meats by lowering the water activity. Sodium chloride is the salt most commonly used in brine solutions, and its usage level varies with the type of product, being 1–2% in sausages, 2–3% in hams, 1.2–1.8% in bacon, and 2–4% in jerkies. Approximately 0.4–0.7% of potassium chloride on a finished-weight basis is used in low-sodium meat products, but it may impart bitter and metallic flavor if used at >0.75%.

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Improving the quality of restructured and convenience meat products

M.M. Farouk , in Processed Meats, 2011

18.3.1 Aesthetics-related quality problems in restructured whole-tissue products

Two of the most important factors affecting the point of purchase decision by consumers are the colour and appearance of meat products. Colour-related problems are a major cause of reduced acceptability of restructured meats ( Hunt and Kropf, 1987). Some of the factors that affect the colour of restructured meats include:

•

raw material condition, such as the oxidative-reductive state of the meat used in restructuring, meat pH and microbiological condition;

•

ingredients, such as the level of salt and its negative effect on colour or phosphates and their beneficial effect on colour; and

•

processing factors, such as boning time (hot versus cold), rigor state (pre-versus post-rigor), particle size reduction, blade tenderisation, temperature, pressure, and packaging (Hunt and Kropft, 1987).

The use of non-uniform coloured meats that can be caused by mixing high and normal pH meats, meats aged for different periods of time, chilled and thawed meats or meat from muscles with predominantly white fibres and those with red can all cause colour and appearance problems in restructured meats. Misalignment of fibres during restructuring such as by restructuring meat with fibres aligned at different directions to the cut surface of steaks can also result in the reduced acceptability of cold-set raw restructured meat products. Colour problems in restructured meats may be related to the method of restructuring and the type of binder used. The colour and overall appearance of raw slices of cold-set beef rolls restructured using ActivaTM binding system were preferred over those restructured using an alginate binding system (Farouk et al., 2005b).

Visual appearance issues have also been reported to arise from the poor dispersion of binders during restructuring (Esguerra, 1994; Mikkelsen and Esguerra, 1996). The authors restructured beef steaks and cubes using alginate and found that undissolved encapsulated acid appeared as small white spots in the steaks and poorly dispersed alginate appeared as red gel spots in raw chilled or thawed restructured cubes. The appearances of the steaks shown in Fig. 18.2 are a good example of an aesthetics-related problems. The cooked beef steak does not look natural owing to the cross-striations on the face of the steak caused by the alignment of muscle fibres parallel instead of perpendicular to the surface of the steak during restructuring. Restructured meats with visible connective tissues, gristle or large fat particles will also be rejected by consumers.

Fig. 18.2. The effect of wrong fibre alignment during restructuring on sliced beef steak appearance.

Colour and appearance problems are more important in cold-set restructured products that are often sold uncooked and/or chilled relative to hot-set restructured products as they are likely to be sold in cooked or frozen form. This is exemplified by the results of a study by Farouk and Swan (1997) in which a consumer panel could not differentiate between the colours of cooked hot-set restructured roast beef prepared from non-uniformed coloured meats including pre-rigor, post-rigor, grass- and grain-finished beef. Farouk et al. (2005a) determined the effect of fibre alignment on the appearance of restructured steaks and found that raw restructured beef steaks with fibres aligned parallel to the cut steak surface were ranked highest in acceptability by a consumer panel compared with steaks with fibres aligned perpendicular or mixed. The panellists indicated their choice was influenced by the colour and appearance of the cut steak surface; they found the most preferred steaks to be the most uniform in appearance, most consistent in colour, and the ones that looked the most natural; and the least preferred ones to have mottled appearance, chunky look and more obviously processed appearance. When the same steaks were cooked, the ones with fibres running parallel to their cut surface were ranked lowest compared with the perpendicular and mixed ones.

The reason for the change in the visual appeal of the parallel aligned steaks from being the highest ranked in the raw state to the lowest in the cooked state was because in the raw state, colour had more influence on the decision of the panellists, as it was more difficult to see the direction of the fibres in relation to the steak surface; the effect of the fibre alignment became more obvious after cooking and the parallel aligned steaks lost their natural-look appeal.

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Applications of Bioactive Seaweed Substances in Functional Food Products

Yimin Qin , in Bioactive Seaweeds for Food Applications, 2018

Bioactive Seaweed Substances for Functional Food Applications 118

6.3.1

Seaweed-Derived Minerals and Their Applications in Functional Foods 119

6.3.2

Seaweed Hydrocolloids and Their Applications in Functional Foods 119

6.3.2.1

Fabricated Food Products 119

6.3.2.2

Restructured Meat Products 122

6.3.2.3

Analog Food Products 123

6.3.2.4

Cold Jellies 123

6.3.2.5

Fat Replacer 124

6.3.2.6

Sausage Casing 124

6.3.2.7

Dairy Products 126

6.3.2.8

Other Functional Food Products 126

6.3.3

Mannitol and Its Applications in Functional Foods 126

6.3.4

Phlorotannins and Their Application in Functional Foods 127

6.3.5

Fucoxanthin and Its Application in Functional Foods 127

6.3.6

Sulfated Polysaccharides and Their Application in Functional Foods 128

6.3.7

Other Seaweed-Derived Functional Food Ingredients 128

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